Housings, covers and guards
Equipment shells, removable covers and protective parts. Review the internal space, component layout, openings, fasteners and appearance before detailing the mold.
Product Development & Manufacturing
Custom Injection Molding
Develop plastic parts that fit, function and work in the complete product.
We help distributors improve existing products, customize for local requirements and develop new molded plastic parts. Product design, material selection, mold tooling, trial samples and manufacturing are connected around your application.
Molded parts for the complete product
Injection molding creates three-dimensional parts with features that serve the product: a cover locates against a housing, a boss receives a fixing, a clip holds a component and a fitting connects to another part.
Share the complete assembly so the visible surfaces, connections, mounting points and functional dimensions can be considered together.
Brackets, clips and mounting parts
Features that locate, retain or support other components. The drawing should identify the mating parts, mounting references, repeated action and required functional checks.
Handles, caps and fittings
Parts used to hold, close, connect or operate a product. Define grip, movement, fit, contact surfaces and the intended use rather than selecting the shape in isolation.
Custom functional components
Molded parts developed around a particular product or assembly. Wall structure, ribs, bosses, snaps and other features are assessed with the material and tooling route.
Choose your project starting point
Improve an existing part
Bring the sample and the problem: assembly difficulty, deformation, a weak feature, an unwanted mark or a change in service conditions.
Customize for your market
Review a current product direction and define the required size, mounting, appearance, material or packing changes.
Develop a new molded product
Start with the user need, application, assembly and expected quantity. DFM helps turn that requirement into a moldable part and a clear tooling brief.
If a mold already exists, include the available tool information. Its suitability, condition, interfaces and sample history need review before a production route is agreed.
Select the resin with the product and mold
Material choice affects how the part fills, cools, shrinks and behaves in use. Appearance, stiffness, impact, movement, temperature, exposure and mating fit should be defined as product requirements.
The material examples below are starting points for a project discussion. The grade and processing fit are confirmed for the actual part.
| Material direction | Discussion focus |
|---|---|
| ABS | Housing geometry, appearance and assembly. |
| PP | Part structure, flexibility and the intended function. |
| PE | Geometry, impact requirement and service conditions. |
| PC | Optical or structural requirement and the selected grade. |
| POM | Moving or fitted features and dimensional requirements. |
Where a specific resin is already required, provide its grade and supporting specification. Changing the resin can affect shrinkage, tool dimensions, surface and the trial plan, so it should be considered before tooling is finalized.
DFM: develop the features before cutting the mold
Design for manufacturability connects the product requirement with a part that can be filled, cooled and released from the mold.
Walls and transitions
Review wall consistency and changes in section. Local thick areas and abrupt transitions influence filling, cooling and the surface that the customer sees.
Ribs and bosses
Develop supporting features with their surrounding walls and fixing method. Their geometry matters to both molding and the finished assembly.
Draft and release
Consider the mold opening direction, release surfaces and features that may require additional tool movement.
Undercuts and snaps
Identify the way these features are formed and released, then relate them to the intended assembly or repeated action.
Visible faces and interfaces
Mark important surfaces, mating dimensions, sealing areas and fixing points so gate, parting and ejector locations can be assessed against them.
A prototype can help review the concept and fit. Molded trials are still required to confirm the behavior produced by the selected resin, mold and process.
The mold connects the part to production
A mold includes more than the shape of the cavity. Its parting arrangement, feed system, cooling, venting, guidance and ejection work together.
| Mold feature | Why it matters to the product |
|---|---|
| Core, cavity and parting | Establish geometry, opening direction and the location of parting features. |
| Runner and gate | Bring material into the cavity and affect filling, visible marks and flow meeting points. |
| Cooling | Influence temperature distribution, shape, dimensions and the production cycle. |
| Venting | Allows displaced air to leave as the cavity fills. |
| Ejection | Releases the cooled part while protecting important features and surfaces. |
Tooling is reviewed against the intended resin, critical dimensions, required appearance, assembly and production program. The trial plan should make clear how the molded result will be assessed.
Match the tool to the production program
Part size, projected area, material, shot requirement, cavity arrangement and mold opening requirements all contribute to machine and tool matching.
The cavity plan also affects tooling investment, filling balance and the production route. It should follow the expected quantity and product maturity rather than an assumed maximum output.
The tool's physical interfaces and operating requirements need to fit the proposed machine. For an existing tool, drawings, setup details and recent samples help establish what must be checked.
No single machine figure defines whether a project can be produced. Send the part and tool information for a specific assessment.
How the molding cycle forms the part
Prepare and plasticize
Prepare the selected material for the process. The screw plasticizes and meters material for the next shot.
Clamp and inject
The mold closes and is held while material enters the cavity through the feed system.
Pack
Holding conditions act during the relevant part of solidification and influence the molded result.
Cool
The part develops sufficient stability for release. Cooling distribution affects shape and dimensions.
Open and eject
The mold opens and the ejection system releases the part. The result is checked against the agreed product requirements.
Filling, holding, cooling and ejection are considered together. Adjusting one stage can affect features created elsewhere in the cycle.
Trial samples turn the design into evidence
A trial establishes what the selected tool, material and process actually produce. It is an opportunity to check the complete part and assembly before the production reference is confirmed.
- Mold and inspect. Check filling, visible surfaces, release condition and the critical dimensions.
- Fit and function. Assemble with the mating parts and apply the agreed product checks.
- Adjust and reassess. Address the observed issues through the appropriate material, process or tooling review.
- Confirm the reference. Record the accepted product, drawing revision, appearance criteria and inspection requirements.
A part that looks complete may still need dimensional or assembly correction. The sample review should therefore follow the features that matter to its use.
Quality checks follow common molding concerns
| Observation | Areas considered during review |
|---|---|
| Short fill or incomplete features | Material preparation, filling, flow path and venting. |
| Flash | Parting condition, tool fit and molding conditions. |
| Sink or local shape change | Wall structure, packing and cooling. |
| Warpage or dimensional change | Material behavior, geometry, cooling and release. |
| Burns, streaks or visible flow features | Material condition, air release and filling behavior. |
| Ejection marks or sticking | Draft, release direction, cooling and ejection support. |
These observations guide investigation; they do not establish a cause by themselves. Inspection and trial results determine what should change.
Identify critical dimensions, visible faces, functional checks and acceptance criteria before samples. Any environmental or performance testing should be tied to the actual product specification.
From the molded part to the assembly
Define the operations after molding with the same care as the tool. Gate treatment, appearance, identification, mating parts, hardware, assembly checks and packing can influence what the customer receives.
Share whether components are delivered separately or as an assembly, which surfaces require protection and how parts will be handled during transport and installation. The proposal should identify the included operations.
When a product combines injection molded parts with extruded sections or metal components, bring the complete interface into the development discussion.
Inside Jizon’s factory
Engineering and manufacturing connect around the complete product. Bring the molded part, mating components and delivery requirements into one discussion so the interfaces and production scope can be developed together.
Questions before starting
Can we begin without a completed CAD model?
An idea, sketch, existing product or sample can begin the discussion. The application, assembly and expected change help establish the design work required.
Can an existing mold be considered?
Yes. Provide tool drawings or available specifications, recent samples, material information and production history. Compatibility and condition must be reviewed.
Can we change material after the mold is built?
It requires review. A different resin can change shrinkage, filling, dimensions and the molding conditions needed by the part.
What tolerances can be achieved?
They depend on the feature, resin, geometry, tooling and process. Identify the dimensions that control fit or function for a project-specific assessment.
Can you help with the whole product?
Yes. Share the mating parts, assembly and application so plastic and metal manufacturing routes can be considered together.
Connect with our other manufacturing processes
Let’s develop your molded plastic product
Send a drawing, sketch or sample, intended use, mating components, material reference, important dimensions, visible surfaces, expected quantity and packing requirements. Include existing mold information when available.